Engine oil spray collector

ABSTRACT

An engine including an oil spray collector is provided. The collector is located on an underside surface of the valve cover to accept a previously identified oil spray from at least one engine component.

TECHNICAL FIELD

The present disclosure relates to engines, and more particularly to features on the walls of engine valve covers and other engine surfaces.

BACKGROUND

Oil emulsion is a common issue experienced by engine systems. Water may condense on the underside surface of the engine's valve cover. During operation of the engine, oil spray may make contact with a large portion of the valve cover's underside surface and mix with the condensed water and emulsify.

U.S. Pat. No. 5,492,086 (the '086 patent) shows an example of structures added to the underside surface of a valve cover. The structures shown in the '086 patent, however, are not designed or located to account for the engine's oil spray or the oil emulsion created.

SUMMARY

In one aspect, the present disclosure provides an engine including a collector located to accept a previously identified oil spray from at least one engine component. In another aspect, the present disclosure provides an engine valve cover including the collector on an underside surface of the valve cover. The collector may include an annular ridge defining a basin inside.

In yet another aspect, the present disclosure provides a method for reducing oil emulsion in an engine. The method includes identifying localized areas of oil spray in the engine and locating a collector over selected localized areas of oil spray. The method may also include designing the collector's shape and size based on characteristics of the oil spray and engine.

Other features and aspects of this disclosure will be apparent from the following description and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of an engine including a valve cover;

FIG. 2 is an enlarged view looking up at the valve cover shown in FIG. 1;

FIG. 3 is a cross-sectional side view of a collector on the valve cover shown in FIG. 2; and

FIG. 4 is a flow diagram of a method for locating and designing collectors.

DETAILED DESCRIPTION

As seen in FIG. 1, an engine 10 includes a bottom end 12 and top end 14. The engine 10 may also include other features not shown, such as fuel systems, air systems, aftertreatment systems, cooling systems, peripheries, drivetrain components, turbochargers, etc. The engine 10 may be any type of engine (internal combustion, gas, diesel, gaseous fuel, natural gas, propane, etc.), may be of any size, with any number of cylinders, and in any configuration (“V,” in-line, radial, etc.). The engine 10 may be used to power any machine or other device, including on-highway trucks or vehicles, off-highway trucks or machines, earth moving equipment, generators, aerospace applications, locomotive applications, marine applications, pumps, stationary equipment, or other engine powered applications.

The engine bottom end 12 includes a block 16 and an oil pan 18 coupled to the bottom of the block 16. A supply of oil 20 is contained within the block 16 and the oil pan 18. Contained within the block 16 is a crankshaft 22, piston 24, and rod 26 connecting the piston 24 to the crankshaft 22. The piston 24 moves within a cylinder 28 portion of the block 16.

The engine top end 14 includes ahead 30, spacer 32, valve cover 34, valve assembly 36, and engine brake 38. The head 30 is coupled to the top of the block 16. The head 30 includes intake and exhaust ports 40 interconnecting the top of cylinder 28 and the intake and exhaust manifolds 42. The spacer 32 may be coupled to the top of the head 30. The spacer 32 may also not be included or may be formed as part of the head 30 or spacer 32. The valve cover 34 is coupled to and extends above the spacer 32.

The valve assembly 36 includes valves 44, valve bridge 46, rocker 48, and cam 50. The valves 44 extend from the top of the cylinder 28, in the ports 40, and through the head 30. The top of valves 44 extend up into an area defined by the spacer 32. The valves 44 may also include valve springs 45 to provide a biasing force. Multiple valves 44 may be connected by a valve bridge 46. The valves 44 or valve bridge 46 is coupled to a rocker 48 that is in contact with a cam 50. The cam 50 rotates to drive the rocker 48 and actuate the valves 44. The valves 44 may also be actuated by other means. All, or a portion of, the valve assembly 36 components may be contained within a valve housing 51.

Under the valve cover 34 and above the valve assembly 36 may be the engine brake 38. In other embodiments, the engine brake 38 is not included. The engine brake 38 includes an oil feed 52 receiving oil from the supply of oil 20 through an oil pump (not shown). The engine brake 38 also includes actuators 54, accumulators 56, and pistons 58, which use the oil 20 and input signals to active the engine brake 38 and act on the rocker 48. The engine brake 38 is contained, at least partially, within and includes brake housing 59.

The valve cover 34 covers the engine brake 38, valve assembly 36, and other engine components. The valve cover 34 may also cover an intake valve or early exhaust valve or other actuation system. The valve cover 34 may include a side wall 60 extending downward along the periphery of a top wall 62. The valve cover 34 also includes an underside surface 64 and outside surface 66.

Oil spray 67 or oil movement is common under the valve cover 34, with oil 20 being splashed against the underside surface 64. The components of the valve assembly 36 and the engine brake 38 use the oil 20 for lubrication and to actuate. As these components, or any other component in the top end 14, move, actuate, or de-actuate, the oil 20 is splashed upwards, creating oil splash or oil spray 67. The oil spray 67 may also be caused as air is displaced and spits up through areas of collected oil 20. Engine 10 vibration or machine vibration may also cause oil spray 67. The oil sprays 67 may be commonly seen to occur in concentrated, localized, and consistent locations. The oil sprays 67 may also be designed to occur in concentrated, localized, and consistent locations. Accordingly, oil sprays 67 commonly hit against the same area of the valve cover 34 underside surface 64 over and over.

As seen looking down on the underside surface 64 of valve cover 34 in FIG. 2, collectors 68 are included partially or in whole on the underside surface 64 of the top wall 62 of valve cover 34. The collectors 68 may also be located partially or in whole on the underside surface 64 of the side wall 60 of valve cover 34. The collector 68 may be welded, brazed, bolted, or otherwise connected, joined, or coupled to the valve cover 34. The collectors 68 may also be formed as an integral part of the valve cover 34. The location of the collectors 68 will vary and may be placed on other portions of the engine 10, where oil spray 67 may occur.

As seen best in FIG. 3, the collectors 68 may be round or circular. The collectors 68 may also be oval, square, rectangular, or another geometric shape and may or may not be symmetric. The collectors 68 may include a base 70 against the underside surface 64 on the top wall 62 of the valve cover 34. The base 70 may also be on side wall 60 or partially on both top wall 62 and side wall 60.

Extending downward from the outside periphery of the base 70 is an outside ramp 72, as seen in FIG. 3. The outside ramp 72 may form a concave curve (as shown), convex curve, or angled straight slope. The outside ramp 72 may also be substantially perpendicular to the base 70 or follow any other downward path.

At the end of the outside ramp 72 is a ridge 74. The ridge 74 forms the lowest portion of the collector 68 as seen in FIG. 3. Ridge 74 may include a ridge peak 75 that may be the lowest point of the collector 68. As seen in FIG. 2, the collector 68 or ridge 74 may be ring shaped or annular, having a beginning portion 76 and end portion 78 that meet to form a full circle or closed loop. A portion of the ridge 74 or outside ramp 72 may also be formed as part of the side wall 60 or other structure within the valve cover 34.

Defined by the inside of the ridge peak 75 is a basin 79. The basin 79 includes an inside ramp 80 and a bottom 81. The inside ramp 80 may be domed with a concave shape (as shown), have a convex shape, or have a straight slope. The inside ramp 80 may also be substantially perpendicular to the base 70 or be another shape. The basin 79 may also include indentations or recessed pockets (not shown).

The bottom 81 may be the deepest point of the basin 79 or may be the deepest point of any indentations or recessed pockets. Bottom 81 may represent a point, multiple points, area, or collection of points. The bottom 81 may be flush with the underside surface 64 or be above or below it. The location of the bottom 81 may be at the center of the basin 79 or skewed to one side or another of the collector 68. The shapes and sizes of the ridge 74 and basin 79 may be formed to correspond to the geometric shape of the collector 68.

The dimensions that follow define the shape and size of one specific embodiment of the collector 68. As described, many other sizes and shapes of collectors 68 are possible. The width or diameter of the base 70 is a base width 82. The width or diameter from the ridge peak 75 to a point opposite is a ridge width 84. The average radius of curvature of the basin 79 is a radius of curvature 88. The distance from the underside surface 64 to the ridge peak 75 is a ridge height 90.

In one specific embodiment, the base width 82 is roughly 2.6 inches and the ridge width 84 is roughly 1.9 inches. Because the collector 68 is round in this specific embodiment, the base width 82 and ridge width 84 represent a diameter. However, in other embodiments, the base width 82 and ridge width 84 may represent a width or length of another geometric shape. Additionally, the base width 82 and ridge width 84 may also be substantially the same in embodiments where the outside ramp 72 extends downward at and angle substantially perpendicular to the base 70.

The radius of curvature 88 is roughly 1.5 inches in the current specific embodiment. The radius of curvature 88 may change over its surface and may have a wide variety of values in other embodiments. The ridge height 90 in the current specific embodiment is roughly 0.4 inches. In other embodiments, the ridge height 90 may vary along its loop from beginning portion 76 to end portion 78. The ridge height 90 may provide clearance between ridge peak 75 and the valve assembly 36 or engine brake 38 or other components under the valve cover 34. The ridge peak 75 may also make contact with or couple to the valve assembly 36 or engine brake 38 or other components under the valve cover 34. The ridge height 90 may also be zero or negative if the collector 68 is recessed in the top wall 62.

The collectors 68 may also extend upwards from the underside surface 64 and not downward. The outside surface 66 may also have raised portions to accommodate the collectors 68.

INDUSTRIAL APPLICABILITY

The valve cover 34 underside surface 64 may have water 92 that has condensed on it or is otherwise present. Water 92 may have condensed while the engine was shut down or otherwise cool. Emulsion may occur when oil spray 67 contacts underside surface 64 and any water 92 that may be present. An emulsion may occur when oil 20 coats or surrounds droplets of water 92 or water 92 coats or surrounds droplets of oil 20. While oil 20 and water 92 may not ordinarily mix, the conditions present in engine 10 may cause them to. The energy introduced from the shaking vibration of the operating engine 10 and the oil sprays 67 may cause the emulsion to occur. This emulsion may effect the lubrication and other performance characteristics of the oil 20 and engine 10.

By locating the collectors 68 over localized areas of oil spray 67, the emulsion of oil 20 may be reduced. The oil spray 67 may be largely contained in, make contact in substantially meaningful proportions, or accepted by the collector 68 or basin 79. Accordingly, the oil spray 67 may not contact other areas of the underside surface 64 in substantially meaningful quantities. A portion of the oil spray 67 may repeatedly contact the same area (the collector 68 or basin 79) and not contact the portions of the underside surface 64 that it may have otherwise. As a result, less water 92 may be in contact with the oil 20 and less emulsion may be formed. The collectors 68 may also be adapted to accept the oil spray 67 from other portions of the engine 10. The collectors 68 may also be located in these other areas of the engine 10.

FIG. 4 illustrates a flow diagram of a method for locating and designing the collectors 68 or a method of reducing oil emulsion 100. The first step 101 of method 100 is to evaluate the engine oil emulsion conditions and the need for collectors 68. The second step 102 is to determine or identify localized areas or locations of the oil spray 67 under the valve cover 34. The areas of the oil spray 67 may be identified using cameras or sensors in an operating engine or test rig, other observation techniques, or by using prediction models. The localized areas of oil spray 67 may also be identified as designed vents or other areas in the valve assembly 36 or engine brake 38 that generate oil spray 67.

The third step 103 is to select collector 68 placement locations. As described above, the collectors 68 may be positioned in a number of locations on the underside surface 64 of the valve cover 34 or engine 10. Any number of collectors 68 may be used, as needed depending on the specific oil sprays 67. Many areas of oil spray 67 may be identified. The most significant, largest, or most effective to treat may be selected for placement of collectors 68.

The fourth step 104 is to design the shape and size of collectors 68 to contain or accept the oil spray 67 identified in step 102. The shape of the collectors 68 may be designed to accommodate the geometry or characteristics of the underside surface 64 where the collector 68 is placed. The shape of the collector 68 may also be adapted to the characteristics of the oil spray 67. For instance, if the oil spray 67 is more of a stream or impacts at an angle, a long and narrow collector 68 may be best suited.

The fifth step 105 is to place the collectors 68 previously designed in step 104 in locations previously identified in step 103. In the sixth step 106, the emulsion formation is reevaluated. In the seventh step 107, steps 102-106 are repeated as needed to achieve the desired results.

Although the embodiments of this disclosure as described herein may be incorporated without departing from the scope of the following claims, it will be apparent to those skilled in the art that various modifications and variations can be made. Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice of the disclosure. It is intended that the specification and examples be considered as exemplary only, with a true scope being indicated by the following claims and their equivalents. 

1. An engine valve cover comprising: an underside surface exposed to engine components; and a collector located on the underside surface to accept a oil spray from at least one engine component.
 2. The engine valve cover of claim 1 wherein the collector further includes a ridge defining a basin inside.
 3. The engine valve cover of claim 2 wherein the basin is concave.
 4. The engine valve cover of claim 2 wherein the ridge is annular.
 5. The engine valve cover of claim 1 further including a top wall and side walls extending from the top wall and wherein the collector is located on the top wall.
 6. The engine valve cover of claim 1 wherein the oil spray is previously identified.
 7. An engine comprising a collector located to accept a oil spray from at least one engine component.
 8. The engine of claim 7 further including a bottom end and top end and wherein the collector is located in the top end.
 9. The engine of claim 8 wherein the top end further includes a valve cover and wherein the collector is located on an underside surface of the valve cover.
 10. The engine of claim 9 wherein the valve cover further includes a top wall and side walls extending from the top wall and wherein the collector is located on the top wall.
 11. The engine of claim 7 wherein the collector further includes a ridge defining a basin inside.
 12. The engine of claim 11 wherein the basin is concave.
 13. The engine of claim 11 wherein the ridge is annular.
 14. The engine of claim 7 wherein the oil spray is previously identified.
 15. A method of reducing oil emulsion in an engine comprising: identifying localized areas of an oil spray in the engine; and locating a collector over selected localized areas of oil spray.
 16. The method of claim 15 further comprising designing the collector's shape and size based on characteristics of the oil spray and engine.
 17. The method of claim 15 wherein the collector is located on the underside of a valve cover.
 18. The method of claim 15 wherein the collector includes a ridge defining a basin inside.
 19. The method of claim 18 wherein the basin is concave.
 20. The method of claim 18 wherein the ridge is annular. 